Paving Block with Improved Illumination

ABSTRACT

A paving block with improved illumination (luminescent paving block) preferably includes a concrete base layer and a photoluminescent layer. The photoluminescent layer is formed on top of the concrete base layer. The concrete base layer is preferably created by combining sand, aggregate, water, pigment and cement to form an uncured concrete mixture. The photoluminescent layer preferably includes very fine aggreagate, cement, water, pigment, sand and a polyester resin infused with a photoluminescent pigment or a silica-based glass material infused with photoluminescent pigment. Further, a light transmitting sealant may be placed over the photoluminescent material.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of International Application SerialNumber PCT/US2020/018755 filed Feb. 19, 2020, which claims priority fromU.S. application Ser. No. 16/373,082 filed Apr. 2, 2019 which are eachhereby incorporated herein by reference in their respective entirety.

FIELD OF INVENTION

The present invention relates generally to outdoor surface constructionand more specifically to a paving block with improved illumination,which provides illumination without the need for electrical power.

DISCUSSION OF THE PRIOR ART

Paving blocks are used for walkways, large public pedestrian areas,driveways, paths and the like. The paving blocks allow ground actionwithout deterioration. Paving blocks, like cement blocks for pathways,can be laid in various patterns that are aesthetically pleasing. Walkwaylighting for pathways have been used along with paving blocks toincrease safety, provide sure footing and visibility. Many walkways areilluminated with low or medium voltage lighting, and must be furnishedwith low-or medium voltage electricity to power an illumination system.There are electrical consumption costs associated with the use ofillumination systems. There are also difficulties in setup of theillumination system, if the walkway is a long walkway or is located at adistance from an electrical connection. A licensed contractor must behired to install electrical supplies for the illumination system.

The use of outdoor lighting is known in the prior art. For example, U.S.Pat. No. 6,027,280 to Connors et. al (Connors) discloses an interlockingpaving block with interior illumination capability. However Conners doesnot allow for non-electrical use of an outdoor light. Similarly, U.S.Pat. No. 5,472,737 to Anders (Anders 737) discloses a photoluminescenthighway paint composition that is painted on highways to aid in driving.

However, Anders 737 does not disclose the use of paving blocks. Lastly,U.S. Pat. No. 6,005,024 to Anders et al (Anders 024) discloses aphotoluminescent overlay that covers existing signs and gives moisturestability to the phosphorescent materials.

However, Anders 024 does not disclose the use of paving blocks.

While the above-described devices fulfill their respective objectionsand requirements, the aforementioned patents do not describe aphotoluminescent paving block that allows for being used for outdoorlighting. Connors makes no provision for non electrical use, since itincludes an insect bulb and wiring.

Anders 737 and 024 only disclose the use of photoluminescent material inconjunction with paving blocks.

Additionally, U.S. Pat. No. 6,665,986 to Kaplan discloses aphosphorescent paving block. US Patent Publication no. 2006/0065879 toBeimel discloses a luminous cementitious composition and methods ofmaking and using the same. U.S. Pat. No. 8,617,638 to Hill discloses amethod of manufacturing photoluminescent pavers at a paver manufacturingfacility. However, U.S. Pat. No. 9,114,422 to Toma et al. discloses apaving block with embedded photoluminescent material. U.S. Pat. No.9,114,422 is hereby incorporated by reference in its entirety.Accordingly, there is a clearly felt need in the art for a paving blockwith improved illumination, which provides illumination without the needfor electrical power.

SUMMARY OF THE INVENTION

The present invention provides a paving block with improvedillumination, which provides illumination without the need forelectrical power. The paving block with improved illumination(luminescent paving block) preferably includes a concrete base layer anda photoluminescent layer. The photoluminescent layer is formed on top ofthe concrete base layer. The concrete base layer is created by combiningsand, aggregate, water, pigment and cement to form an uncured concretemixture. The photoluminescent layer preferably includes very fineaggregate, cement, water, pigment, sand and a polyester resin infusedwith a photoluminescent pigment or a silica-based glass material infusedwith photoluminescent pigment. Further, a light transmitting cover maybe placed over a cured photoluminescent layer.

Accordingly, it is an object of the present invention to provide aluminescent paving block, which has all of the advantages of the priorart for outdoor lighting and none of the disadvantages.

It is further object of the present invention to provide a luminescentpaving block, which may be easily and efficiently manufactured andmarketed. It is yet a further object of the present invention to providea luminescent paving block, which has a low cost of manufacture withregard to both materials and labor.

It is yet a further object of the present invention to provide aluminescent paving block, which requires no wiring, no electrical powerconsumption and no installation by an electrical contractor.

Finally, it is another object of the present invention to provide aluminescent paving for outdoor lighting that is aesthetically pleasing.

These and additional objects, advantages, features and benefits of thepresent invention will become apparent from the following specification.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a luminescent paving block reflectinglight in accordance with the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

With reference now to the drawing, and particularly to FIG. 1, there isshown a perspective view of a luminescent paving block 1. Theluminescent paving block 1 includes a concrete base layer 10 and aphotoluminescent layer 12. The photoluminescent layer 12 is formed ontop of the concrete base layer 10. The concrete base layer 10 ispreferably created by combining sand, aggregate, water pigment andcement to form an uncured concrete mixture. The photoluminescent layer12 preferably includes very fine aggregate, cement, water, pigment, sandand a polyester resin infused with a photoluminescent pigment or asilica-based glass material infused with photoluminescent pigment.Further, a light transmitting sealant may be placed over thephotoluminescent layer 12. In some embodiments of the present invention,the sand in the photoluminescent layer 12 includes at least somephotoluminescent sand.

The photoluminescent pigment preferably includes strontium aluminatedoped with europium. The polyester resin is mixed with the strontiumaluminate pigment to form a polyester resin mixture. The polyester resinis mixed with the strontium aluminate pigment to form an evenlydistributed suspension, and is poured into shallow forms to cure andharden. When the polyester resin mixture is fully cured, the hardenedpolyester resin mixture is crushed in a hammer-mill or with any othersuitable device to create a mixture of randomly sized chips or particlesto form polyester resin mixture fragments.

The silica-based glass material is mixed with the strontium aluminatepigment to form a silica-based glass mixture. The silica-based glass ismixed with the strontium aluminate pigment to form an evenly distributedsuspension, and is poured into shallow forms in preparation of firing ina glass kiln. After the silica-based glass mixture is fully fired, theglass is allowed to cure and harden. The fully cooled and curedsilica-based glass mixture is then crushed with a hammer-mill or withany other suitable device to create a mixture of randomly sized chips orparticles to form silica-based glass fragments.

The following dimensions are given by way of example and not by way oflimitation. When the luminescent paving block has a thickness of about2⅜ inches. The concrete base layer 10 preferably has a thickness ofbetween 1⅞ to 2⅛ inches. The photoluminescent layer 12 preferably has athickness of no greater than 0.5 inches. The concrete base layer 10 iscreated by combining the sand, the aggregate, water, pigment and thecement to form an uncured concrete mixture. The uncured concrete mixtureis poured into a paving block mold (not shown) to the preferred height.The concrete base layer 10 is then compressed with a hydraulic press tofurther drive out any gaps or voids, and to enhance durability of theconcrete base layer 10 to enhance its ability to withstand rated loadsand environmental forces. The photoluminescent layer 12 is created bycombining the very fine aggregate, the sand (which may includephotoluminescent sand), the cement, water, pigment, and a polyesterresin infused with a photoluminescent pigment or a silica-based glassmaterial infused with photoluminescent pigment to form an uncuredphotoluminescent mixture. The uncured photoluminescent mixture is pouredover the uncured concrete mixture. The photoluminescent layer 12 is thencompressed with a hydraulic press to further drive out any gaps orvoids, and to enhance durability of the photoluminescent layer 12 toenhance its ability to withstand rated loads and environmental forces.The paving block mold is then vibrated on a shaker table. The shakertable is a device well known in the art, which is designed to agitatethe uncured concrete mixture to drive out any gaps, voids or air spaces.Additionally, the cast concrete block 10 is allowed to cure for up to 28days in a controlled environment. Finally, when fully dry and cured, thepaving block 1 is subjected to a light surface grinding, which removesexcess concrete material from a top surface and the sand and thepolyester resin mixture fragments or the silica-based glass fragments onthe surface of the luminescent paving block 1. A light transmissivesealant including a methyl methacrylate or polyurethane material may beapplied in the form of spray, after the paving block 1 is ground. Thelight transmissive sealant is allowed to dry for 24 hours, before theluminescent paving block 1 is ready to be inventoried and shipped.

While particular embodiments of the invention have been shown anddescribed, it will be obvious to those skilled in the art that changesand modifications may be made without departing from the invention inits broader aspects, and therefore, the aim in the appended claims is tocover all such changes and modifications as fall within the true spiritand scope of the invention.

What is claimed is:
 1. A method of manufacturing a paving block withembedded photoluminescent material. comprising the steps of: mixingsand, aggregate, water and cement to form an uncured concrete mixture;providing at least one of the following: a photoluminescent mixture of apolyester resin infused with a photoluminescent pigment; or aphotoluminescent mixture of a silica-based glass material infused with aphotoluminescent pigment; curing said photoluminescent mixture, breakingsaid photoluminescent mixture into randomly sized chips or particles toform photoluminescent fragments; mixing said photoluminescent fragments,sand, cement and water to form an uncured luminescent mixture; providinga paving block mold; pouring said uncured concrete mixture into thepaving block mold; and pouring said uncured luminescent mixture tosubstantially fill said paving block mold.
 2. The method ofmanufacturing a paving block with embedded photoluminescent material ofclaim 1, further comprising the step of: allowing said contents in saidpaving block mold to cure for a set period of time in a controlledenvironment to form a paving block.
 3. The method of manufacturing apaving block with embedded photoluminescent material of claim 2, furthercomprising the step of: grinding a top surface of said paving block toremove excess concrete material and expose a photoluminescent layer. 4.The method of manufacturing a paving block with embeddedphotoluminescent material of claim 3, further comprising the step of:applying a transmissive sealant to cover said photoluminescent layer. 5.The method of manufacturing a paving block with embeddedphotoluminescent material of claim 1, further comprising the step of:pouring said photoluminescent mixture into a shallow form to allow it tocure and harden.
 6. The method of manufacturing a paving block withembedded photoluminescent material of claim 1, further comprising thestep of: firing said silica based glass material infused with saidphotoluminescent pigment in a kiln.
 7. The method of manufacturing apaving block with embedded photoluminescent material of claim 1, furthercomprising the step of: vibrating said paving block mold on a shakertable.
 8. A method of manufacturing a paving block with embeddedphotoluminescent material, comprising the steps of: mixing sand,aggregate, water and cement to form an uncured concrete mixture;providing a photoluminescent mixture of a polyester resin infused with aphotoluminescent pigment; curing said photoluminescent mixture, andbreaking said photoluminescent mixture into randomly sized chips orparticles to form photoluminescent fragments; mixing saidphotoluminescent fragments, sand, cement and water to form an uncuredluminescent mixture; providing a paving block mold pouring said uncuredconcrete mixture into the paving block mold; and pouring said uncuredluminescent mixture to substantially fill said paving block mold.
 9. Themethod of manufacturing a paving block with embedded photoluminescentmaterial of claim 8, further comprising the step of: allowing saidcontents in said paving block mold to cure for a set period of time in acontrolled environment to form a paving block.
 10. The method ofmanufacturing a paving block with embedded photoluminescent material ofclaim 9, further comprising the step of: grinding a top surface of saidpaving block to remove excess concrete material and expose aphotoluminescent layer.
 11. The method of manufacturing a paving blockwith embedded photoluminescent material of claim 10, further comprisingthe step of: applying a transmissive sealant to cover saidphotoluminescent layer.
 12. The method of manufacturing a paving blockwith embedded photoluminescent material of claim 8, further comprisingthe step of: pouring said photoluminescent mixture into a shallow formto allow thereof to cure and harden.
 13. The method of manufacturing apaving block with embedded photoluminescent material of claim 8, furthercomprising the step of: firing said silica-based glass material infusedwith said photoluminescent pigment in a kiln.
 14. The method ofmanufacturing a paving block with embedded photoluminescent material ofclaim 8 further comprising the step of: vibrating said paving block moldon a shaker table.
 15. A method of manufacturing a paving block withembedded photoluminescent material, comprising the steps of: mixingsand, aggregate, water and cement to form an uncured concrete mixture;providing a silica-based glass material infused with saidphotoluminescent pigment; curing said photoluminescent mixture, andbreaking said photoluminescent mixture into randomly sized chips orparticles to form photoluminescent fragments; mixing saidphotoluminescent fragments, sand, cement and water to form an uncuredluminescent mixture; providing a paving block mold; pouring said uncuredconcrete mixture into the paving block mold; and pouring said uncuredluminescent mixture to substantially till said paving block mold. 16.The method of manufacturing a paving block with embeddedphotoluminescent material of claim 15, further comprising the step of:allowing said contents in said paving block mold to cure for a setperiod of time in a controlled environment to form a paving block. 17.The method of manufacturing a paving block with embeddedphotoluminescent material of claim 16, further comprising the step of:grinding a top surface of said paving block to remove excess concretematerial and expose a photoluminescent layer.
 18. The method ofmanufacturing a paving block with embedded photoluminescent material ofclaim 17, further comprising the step of: applying a transmissivesealant to cover said photoluminescent layer.
 19. The method ofmanufacturing a paving block with embedded photoluminescent material ofclaim 15, further comprising the step of: pouring said photoluminescentmixture into a shallow form to allow thereof to cure and harden.
 20. Themethod of manufacturing a paving block with embedded photoluminescentmaterial of claim 15, further comprising the step of: firing saidsilica-based glass material infused with said photoluminescent pigmentin a kiln.